Integrated bicycle control device

ABSTRACT

An integrated bicycle control device has a handlebar portion of a bicycle handlebar assembly. The handlebar portion has a body with a gripping portion adjacent a distal end of the body and a transition portion spaced from the gripping portion. A compartment may be formed in the transition portion and an opening in the body may permit access to the compartment. An actuator is disposed near the distal end of the gripping portion. A control element and/or other elements or circuitry may be disposed within the compartment.

BACKGROUND 1. Field of the Disclosure

The present disclosure is generally directed to control of bicyclecomponents, and more particularly to remote actuation via a wirelesssystem integrated as part of a bicycle handlebar component.

2. Description of Related Art

Remote actuation of bicycle components using control devices isgenerally known in the art. Existing bicycle control devices of thistype are designed to be inserted into the ends of bicycle handlebars.These devices provide either a wired signal or a wireless signal tooperate a bicycle component located elsewhere on the bicycle. Thesedevices are designed to fit in the free end of a bicycle handlebar. Suchdevices are thus entirely contained within a gripping portion of thehandlebar.

One problem with such devices is that the rider's hands may interferewith the wireless signal generated and/or received by the controldevice. This is because the antenna is located as part of the controldevice within the gripping portion of the handlebar. The rider's handswrap around the gripping portion of the handlebar and thus can interferewith the wireless signals. In some of these devices, the user input forthe control device is a part of the junction box of the device. In someof these devices, the user input may be separate from the junction box,which requires external connection wires. In these devices with aseparate use user input, the junction box is still within the grippingportion and the antenna is located proximate to the gripping portion atthe handlebar end.

U.S. Pat. No. 9,821,884 discloses one such control device or bicycleoperating device that is configured to be press fit into a free end ofone of the handlebars. The operating device controls a bicycle componentvia the transmission of wired or wireless signals. The operating deviceis located entirely within the gripping portion of the handlebar.

U.S. Publication No. 2017/0080993 discloses a bicycle control devicespecifically for wirelessly controlling a bicycle component. The bicyclecontrol device is again arranged in a handlebar of the bicycle. Theantenna is attached to the operator control, which is located outside ofthe handlebar, but which is also located at the gripping element of thehandle bar.

U.S. Pat. No. 9,858,807 discloses a wireless control system forcontrolling an external device. The control system is inserted into anend of the handlebar. The entire control system is located within thegripping portion of the handlebar, including the antenna. The user inputdevice is located away from the free end of the bar, but external wiresare required to connect the user input to the junction box.

The external wires used to connect the user input devices to thejunction boxes of these types of devices can create problems anddisadvantages for the rider and during assembly of the bicycle. Thewires can complicate the assembly process or become damaged ordisconnected, rendering the control device, and thus the bicyclecomponent, inoperative during use.

SUMMARY

In one example, according to the teachings of the present disclosure, anintegrated bicycle control device includes a handlebar portion of abicycle handlebar assembly. The handlebar part has a body with agripping portion adjacent a distal end of the body and a transitionportion spaced from the gripping portion. A compartment is formed in thetransition portion and an opening in the body permits access to thecompartment. An actuator is disposed at or near the distal end of thegripping portion. A control element is disposed within the compartment.The control element includes a housing and a controller in the housing.The controller is configured to generate a signal in response toactuation of the actuator.

In one example, the handlebar part can include a mounting portionadjacent a proximal end of the body. The transition portion can bedisposed between the mounting portion and the gripping portion.

In one example, the handlebar part can be bent between a mountingportion and the gripping portion, where the transition portion isbetween the mounting and gripping portions.

In one example, the transition portion can have a cross section shapethat is different from a cross section shape of the gripping portion, amounting portion, or both.

In one example, the gripping portion can have an interior with a maximumwidth or diameter that is smaller than a maximum width or diameter ofthe compartment within the transition portion.

In one example, the control element can have a size that is too large tofit within an interior of the gripping portion but not too large to fitwithin the compartment within the transition portion.

In one example, the opening into the body can be disposed on a top ofthe body.

In one example, the opening into the body can be disposed on a side ofthe body.

In one example, the handlebar part can be a bar extension having amounting portion adjacent a proximal end of the body. The bar extensioncan be configured to extend forward on a bicycle when the mountingportion is connected to the bicycle.

In one example, the bicycle control device can include a removable coverattachable to the body to cover the opening and close the compartment.The removable cover and the opening can be positioned on a side of thebody.

In one example, a portion of the transition section can be transparentto radio frequency transmission signals. For example the portion may beformed of a material operable to allow the passage of radio frequencysignals, such as a plastic or other material.

In one example, a radio frequency transparent portion can be transparentto radio frequency transmission signals and can be a removable coverattachable to the body to cover the opening and close the compartment.

In one example, the body can be made from a carbon fiber material andthe cover can be made from a material other than a carbon fibermaterial.

In one example, the integrated bicycle control device can include abattery or power supply case coupled to the housing. The power supplycase can be configured to contain a battery for providing power to thecontroller. A removable cover can close off the power supply case.

In one example, the integrated bicycle control device can include abattery for providing power to the control element. The battery can bepositioned remote from the control element.

In one example, the integrated bicycle control device can include awireless communication device, for example an antenna and/or otherassociated circuitry, that can be in communication with the controller.

In one example, the antenna can be positioned along the transitionportion of the handlebar part.

In one example, the gripping portion can be adjacent a distal end of thebody.

In one example, the actuator can be connected by a cable to the controlelement.

In one example according to the teachings of the present disclosure, ahandlebar part of a bicycle handlebar assembly includes a body having agripping portion and a transition portion spaced from the grippingportion. A compartment is formed in the transition portion and anopening is in the body to permit access to the compartment. A removablecover is attachable to the body to cover the opening and close thecompartment. A control device is integrated into the body. The controldevice has an actuator coupled to the handlebar part adjacent thegripping portion. A control element is received within the compartmentand includes a controller configured to generate a signal in response toactuation of the actuator and a communication module configured totransmit the signal. The control device also includes an antenna and apower supply for providing power to the controller and the communicationmodule.

In one example, the handlebar part can include an LED in the controlelement. The LED can be visible from outside the handlebar part.

In one example, the handlebar part can be a bar extension configured tobe connected to a handlebar assembly.

In one example, the body can have a mounting portion adjacent a proximalend of the body. The transition portion can be disposed between themounting portion and the gripping portion.

In one example, the opening can be on a top of the body.

In one example, the opening can be on a side of the body.

In one example, the antenna can be provided as a part of the controlelement.

In one example, the power supply can be provided as a part of thecontrol element.

In one example according to the teachings of the present disclosure, anintegrated bicycle control device includes a handlebar part of a bicyclehandlebar assembly. The handlebar part has a body with a grippingportion adjacent a distal end of the body, a mounting portion adjacent aproximal end of the body, and a transition portion spaced from anddisposed between the gripping portion and the mounting portion. Acompartment is formed in the body and an opening in the body permitsaccess to the compartment. An actuator is disposed at or near the distalend of the gripping portion. A control element is received in thecompartment and includes a housing and a controller in the housingconfigured to generate a signal in response to actuation of theactuator. An antenna is in communication with the controller and ispositioned along the body spaced from the distal end and the grippingportion. The actuator is connected to the control element.

In one example, the antenna can be disposed along the transition portionof the body.

In one example, the compartment can be in the transition portion.

In one example, the antenna can be in the housing of the controlelement.

BRIEF DESCRIPTION OF THE DRAWINGS

Objects, features, and advantages of the present disclosure will becomeapparent upon reading the following description in conjunction with thedrawing figures, in which:

FIG. 1 shows a side view of one example of a bicycle including anintegrated bicycle control device according to the present disclosure.

FIG. 2 shows a top view of the handlebars and handlebar extensions ofthe bicycle of FIG. 1.

FIG. 3 shows a side view of one handlebar extension, shown in phantom,such as the handlebar extensions shown in FIGS. 1 and 2, and depicts oneexample of an integrated bicycle control device according to the presentdisclosure.

FIG. 4 shows a partial exploded perspective and reverse side view of thehandlebar extension and integrated bicycle control device of FIG. 3.

FIGS. 5A and 5B show opposite side perspective views of one example of acontrol element of an integrated bicycle control device, such as thatdepicted in FIGS. 3 and 4, and according to the present disclosure.

FIG. 6 shows an exploded perspective view of the control element ofFIGS. 5A and 5B.

FIG. 7 shows a side view of the control element of FIG. 5A and with acover panel removed.

FIG. 8 shows a view of wiring and connectors for connecting the controlelement to an actuator of an integrated bicycle control device, such asthat shown in FIGS. 3 and 4, and according to the present disclosure.

FIG. 9 shows a side view in cross section of another example of ahandlebar extension and including an integrated bicycle control deviceaccording to the present disclosure.

FIG. 10 shows a partial exploded perspective and side view of thehandlebar extension and integrated bicycle control device of FIG. 9.

FIG. 11 shows a side view in cross section of another example of ahandlebar extension and integrated bicycle control device according tothe present disclosure.

FIG. 12 shows a side view in cross section of another example of ahandlebar extension and integrated bicycle control device according tothe present disclosure.

FIGS. 13-21 show various alternative examples of handlebar extensionsand integrated bicycle control devices and arrangements according to thepresent disclosure.

DETAILED DESCRIPTION OF THE DISCLOSURE

An integrated bicycle control device is disclosed herein that solves orimproves upon one or more of the above-mentioned and/or other problemsand disadvantages with prior known control devices. The disclosedintegrated bicycle control device includes a control element and anactuator mounted to and integrated with a handlebar or a handlebarextension of a bicycle. The integrated bicycle control device is mountedto a handlebar or handlebar extension of a bicycle with the controlelement, including an antenna, in a position that is spaced from a ridergripping portion of the handlebar or extension. The actuator is mountedat or adjacent the gripping portion of the handlebar or handlebarextension. The bicycle can include two of the integrated bicycle controldevices, one mounted to each handlebar or handlebar extension. Theintegrated bicycle control device may be configured as a part of or tocontrol an electronic shift system to wirelessly transmit and/or receiveshift signals with an electronic shift component of the bicycle. Theintegrated bicycle control device has a power supply unit and can haveone or more inputs or jacks for connecting to remote actuators locatedelsewhere on the bicycle.

The disclosed integrated bicycle control device may position a wirelesscommunicator part, such as an antenna, at a different location from thegripping portion within a handlebar or handlebar extension so that arider's hand does not interfere with the wireless signals. Further, inan embodiment, the disclosed integrated bicycle control device mayinclude auxiliary ports or jacks to connect additional, remoteactuators, i.e., user input devices (buttons, levers, etc.) to thedevice through auxiliary cables. Thus, a remote actuator can be used tooperate the integrated bicycle control device.

The disclosed integrated bicycle control device may be configured toinclude a user input (for example, an actuator) and a control elementthat are integrated within a handlebar extension for a time trial (TT)or triathlon (TRI) bicycle. However, the disclosed integrated bicyclecontrol device can be utilized and integrated with a handlebar orhandlebar extension on other types of bicycles as well. The disclosedintegrated bicycle control device includes a user input or actuator,such as a button, located at a free end of a handlebar or handlebarextension. The actuator or user input is connected to a control elementin a transition portion of the handlebar or handlebar extension, spacedfrom a gripping portion. The control element can include at least oneantenna, a power source, and auxiliary connectors to connect to remotelyplaced user input devices, other input devices, actuators, or the like.

The integrated nature of the disclosed control device makes the deviceeasier to assemble because a user does not need to deal with routing andattaching cables or with mounting the actuator or control element.Further, all the components and any wires are located inside thehandlebar or handlebar extension. Thus, the disclosed integrated bicyclecontrol device can provide a clean look and aerodynamic benefits.Additionally, because the disclosed integrated bicycle control device isa fully integrated system within a handlebar or handlebar extension,there is an added benefit of not having to design an actuator to fitinside or on an end of different handlebars or handlebar extensions withvarious geometries.

Various examples of integrated bicycle control devices are disclosed anddescribed herein. The disclosure is not limited to only those specificexamples and component combinations and arrangements. Features of eachof the disclosed examples may be used alone or in combination with anyone or more features of the other integrated bicycle control deviceexamples and in other combinations thereof.

Those having ordinary skill in the art should understand that thedrawings and detailed description provided herein are for illustrationonly and do not limit the scope of the invention or the disclosure. Theappended claims define the scope of the invention and the disclosure.The terms “first”, “second,” and the like, as well as “front”, “rear,”“left”, “right”, and the like are used for the sake of clarity. Suchterms and similar terms are not used herein as terms of limitation.Further, such terms refer to bicycle mechanisms that are conventionallymounted to a bicycle and with the bicycle oriented and used in astandard manner, unless otherwise indicated.

Turning now to the drawings, FIG. 1 depicts a bicycle 50 with a frame52, a front wheel 54 coupled to a fork 56 of the frame, and a rear wheel58 coupled to seat stays 60 and chain stays 62 of the frame. The wheels54, 58 support the frame 52 above a surface on which the bicycle 50 cantravel in a forward direction indicated by the arrow ‘A’. The bicycle 50has a handlebar assembly 64, described further below, that is mounted toa head tube 66 of the frame 52. The bicycle 50 also has a seat 68carried by a seat post 70 received in a seat tube 72 of the frame 52.The bicycle 50 may have one or both of a front gear changer 74 and arear gear changer 76 mounted to the frame 52. The gear changers 74, 76may be electromechanical derailleurs, for example. The bicycle 50includes a multiple-geared drive train 78 with one or more chainrings 80driven by a crank assembly 82, which has two crank arms 84 and twopedals, respectively 86. The chainrings 80 may be connected to aplurality of sprockets 88 at the rear wheel 58 by a chain 90. Thebicycle 50 as described above is known in the art.

In the disclosed example, the handlebar assembly 64, as shown in FIGS. 1and 2, is a TT or TRI type handlebar arrangement. The handlebar assembly64 thus has a stem 92 coupling the assembly to the head tube 66 and apursuit bar 94 coupled to the stem and having left-hand and right-handbar segments 94L and 94R. The handlebar assembly 64 in this example alsohas a pair of aero bars or handlebar extensions, hereinafter identifiedas bar extensions 96 (when referred to herein generally), including aleft-hand bar extension 96L and a right-hand bar extension 96R (whenreferred to herein specifically). The bar extensions 96 are mounted toand project forward from the pursuit bar 94 in this example. Thehandlebar assembly 64 also has a pair of elbow or forearm cradles 98(when referred to herein generally), i.e., elbow or forearm supports,including a left-hand support 98L and a right-hand support 98R (whenreferred to herein specifically). The cradles 98 are also mounted to thepursuit bar 94 in this example and the bar extensions 96 may be mounteddirectly to the cradles 98 and thus indirectly to the pursuit bar 94.

In this example, the bicycle 50 includes a brake system. The brakesystem includes a brake lever 100 that is movably connected to a forwardend of each of the pursuit bar segments 94L, 94R, though only one isshown in FIG. 1. The brake levers 100 operate components of the brakingsystem of the bicycle 50. In one example, the brake system can includeone or both of a hydraulic or cable actuated front brake mechanism 102coupled to the front wheel 54 via a hydraulic line or mechanical cable106 and a hydraulic or cable actuated rear brake mechanism 104 coupledto the rear wheel 58 through a hydraulic line or mechanical cable 108.As noted above, the brake system can be a hydraulic actuated system or amechanical actuated system and both are known in the art.

Referring to FIGS. 1-4, the bicycle 50 in the disclosed example has atleast one integrated bicycle control device 120, hereinafter the“control device 120”, which can be mounted to a portion of the handlebarassembly 64. Referring to FIGS. 3 and 4, in this example the controldevice 120 is integrated into one of the bar extensions 96, which can beeither the left-hand bar 96L or the right-hand bar 96R. As shown, eachof the bar extensions 96L, 96R can include a separate control device120. Though not shown herein, the control device or devices 120 caninstead be integrated into one of or both of the pursuit bar segments 94L, 94R, if desired. In other examples, the handlebar assembly may be adifferent type, such as a drop bar type, a bullhorn type, a bullmoosetype, a flat type, a riser type, or any other type of handlebar styleand design. The disclosed control device 120 can be integrated intothese types of handlebars, if desired.

As shown in FIGS. 3 and 4, the bar extension 96 has somewhat of a tubeshaped or tubular body 118. The body 118 can be entirely hollow or canbe partially hollow with a race or bore to receive wires through thebody. The body 118 of the bar extension 96 has a clamping or mountingportion 122 at a proximal end P of the bar. The mounting portion 122 isconfigured to be clamped or otherwise mounted, secured, fastened,joined, attached, or connected to the cradle 98 or the pursuit bar 94.The body 118 of the bar extension 96 also has a gripping portion 124 ata distal or free end D of the bar. The mounting end 122 and grippingportion 124 are joined to one another by a central transition portion126 between the two ends. Depending on the type of handlebar assemblyutilized, the mounting portion may be different to accommodate adifferent, direct type of attachment to a bicycle, such as to the headtube 66 of the bicycle 50, or attachment to another part of thealternative assembly. In this example, the handlebar assembly has twogripping portions 124, one on each of the bar extensions 96L and 96R. Inone example, the gripping portions are at the distal ends but in otherexamples, the gripping portions may be near or adjacent the distal ends,but not entirely at the distal ends. In other examples, the barconfiguration may result in the handlebar assembly having at most onlyone gripping portion accommodating both of a rider's hands or more thantwo possible gripping portions accessible for the rider's hands.

The shape of the body 118 of the bar extension 96 in this example, orthe shape of another type of handlebar, can vary from the examples shownand described herein. In this example, the body 118 of the bar extension96 has a relatively straight mounting portion 122, a slight upwardlycurved transition portion 126, and a slight downwardly curved grippingportion 124. Other shapes are certainly possible within the scope of thepresent disclosure. Further, the bar extension, or other type ofhandlebar, can also be made from any suitable materials such as carbonfiber, aluminum, steel, composite, or other suitable materials and canbe made from any suitable manufacturing process.

In this example, as shown in FIGS. 3 and 4, the body 118 of the barextension 96 is at least partially hollow and thus defines an interior130 along the tubular shape. An opening 132 is provided along at leastpart of the transition portion 126 of the body 118. In this example, theopening 132 is formed on a top side of the body 118 and opens into areceiving space or compartment 133, which is in and is a part of theinterior 30 of the body. In other examples, as discussed below, theopening maybe located on a different side of the body. The cross-sectionshape of the body 118 of the bar extension 96 can vary over its length.In one example, a maximum width or diameter of the compartment in thetransition portion 126 can be wider than a maximum width or diameter ofan interior of the gripping portion 124, and/or the wall thickness canbe more robust in the transition portion as compared to the grippingportion to provide rigidity and strength to the structure. The shape ofthe transition portion 126 can also be configured to accommodateinstallation and integration of the control device 120 into the barextension 96, as discussed below. The shape and/or size of the grippingportion 124 may be such that the control device or one or more of itscomponents are too large to fit within the gripping portion and yet thesize and/or shape of the compartment within the transition portion 126may accommodate the control device or its components.

Still referring to FIGS. 3 and 4, the basic components of the controldevice 120 are now described. In this example, the control device 120includes a control element 134 positioned in the compartment 133accessible through the opening 132 in the body 118 of the bar extension96. The term control element is used herein to generally or genericallydefine the electrical component assembly or base componentry thatcontains or includes the bulk of the electronic parts of the controldevice 120. The term is not intended to specifically limit the overallconstruction of the electronics assembly or base componentry. Thus, thecontrol element may otherwise be, or be identified as, a junction box, aprocessor housing, a component unit or assembly, an electronics unit orassembly, or the like. The control device 120 also includes a user inputmechanism or actuator 136 positioned at the distal end D of the grippingportion 124 on the body 118. The control device 120 further includeswires or cables, which include, in part, a cable C configured to extendalong the interior 130 of the body 118 from the transition portion 126to the gripping portion 124 to connect the control element 134 to theactuator 136. The wires or cables, in part, can also include auxiliarywires or cables R extending along the interior 130 between thetransition portion 126 and the mounting portion 122 for purposesdescribed below.

The control device 120, including the control element 134, is installedin the compartment 133 through the opening 132. A cover 144 is removablyattachable to the body 118 over the opening 132 to close of thecompartment 133. The cover 144 can be secured to the body 118 usingfasteners, such as screws 146, or by other suitable methods. The body118 may include mounting holes 148 adjacent the opening 132. The body118 may also include inserts 150 secured within the body and alignedwith the mounting holes. The inserts 150 can be plugged into themounting holes 148 and can be glued, press fit, friction fit, welded,co-molded, or the like to secure them in place. The inserts 150 can beconfigured to receive and engage fasteners, such as the screws 146, toattach the cover 144 to the body. The cover 144 can be made from thesame material as the body 118 of the bar extension 96 or can be madefrom a different material. In one example, the body 118 can be made fromcarbon fiber and the cover 144 can be made from a less expensive plasticmaterial or can be a metal, such as a cast aluminum or a stamped steel.In an example the body 118 is made from carbon fiber and the cover 144is not made from carbon fiber.

The control element 134 in this embodiment can be larger in size than adiameter of the gripping portion 124 or the mounting portion 122, asnoted above. Thus, the control element cannot be installed by being fedinto the distal and D or the proximal end P. Thus, the opening 132 andcompartment 133 are provided in the transition portion 126, which canhave a larger size in cross section than other parts of the body 118.The opening 132 and compartment 133 can be sized and shaped toaccommodate different sized control elements 134, while maintaining adesired or standard smaller size and/or shape for the mounting portion122 and gripping portion 124.

In the disclosed example, the actuator 136 can be a standard off theshelf part, such as a button type actuator, and can include adepressible button 152 received within a housing 154. The housing 154can be configured to be press fit into the open distal end D of thegripping portion 124 on the body 118 of the bar extension 96. In thisexample, the housing includes a press fit mechanism 156 to help retainthe actuator 136 in the distal end D. Other methods or mechanisms may beutilized to secure the actuator in the distal end D, as is describedfurther below. In this example the retention or press fit mechanism 156is carried on the housing 154 of the actuator 136. The mechanism 156includes a plurality of flexible, circumferential webs or discs 158spaced apart lengthwise along the housing 154. The discs or webs 158 arelarger in diameter than the interior diameter of the distal end D of thebody 118. Thus, the discs or webs 158 are sized to deformably andsnuggly fit within the interior of the distal end D to help secure theactuator 136 in place. The webs or discs 158 may also be made from amaterial exhibiting characteristics to increase the surface frictionbetween the mechanism 156 and body 118 as well. The interior 130 of thebody 118 at or near the distal end D may also be modified or adapted toinclude a feature or features to aid in retaining the actuator attachedto the distal end.

FIGS. 5A, 5B, 6, and 7 illustrate the control element 134 in greaterdetail. Referring to these figures, the control element 134 of thecontrol device 120 in this example is a self-contained electricalassembly. The control element 134 includes electronic componentry foroperating a bicycle component, such as one of the electromechanical gearchangers 74, 76. The control element 134 has a housing 160 or case andthe electronic componentry of the control element is contained in orcarried by the housing. The control element 134 generally has acomponent portion 162, a power supply unit 164, and a connection portion166, each defined at least in part by the housing 160. Each of theseportions is described in greater detail below.

The component portion 162 is defined in part by a cavity 168 definedwithin an interior of the housing 160 and a cover 170, which can besecured by fasteners 172 to the housing. The cover 170 can be secured tothe housing 160 to close off the cavity 168 and exclude water and othercontaminants from entry into the cavity. A seal 174 may be interposedbetween the cavity 168 and the cover 170. The seal 174 may be a rubberseal membrane or layer, or any suitable material that satisfactorilyseals the cavity 168 to prevent ingress of moisture or contaminants.

The component portion 162 in this example has a printed circuit board(PCB) 176 is disposed within the sealed cavity 168. Various electroniccomponentry may be mounted on or connected to the PCB 176. The PCB 176may include a communication module 178 configured to transmit signalsfrom the control device 120. In one example, the communication module178 may be configured for wireless transmission of signals in the formof electromagnetic radiation (EMR), such as radio waves or radiofrequency signals. Optionally, the communication module 178 may also beconfigured to receive signals. In one example, the communication module178 may be configured to receive signals, which may be in the form ofEMR such as radio waves or radio frequency signals. The communicationmodule 178 can include or can be a transmitter or a transceiver. The PCB176 may also include an antenna 180 that is in operative communicationwith the communication module 178 to send and optionally also receiveEMR signals. The antenna 180 may be any device designed to transmitand/or receive EMR (e.g. TV or radio) waves.

In the disclosed example, the antenna 180 is on the PCB 176 in aposition where it will be able to send signals without significantinterference from the structure of the control device 120. As discussedbelow, the control device 120 is also positioned relative to the barextension such that there is no significant interference from a rider'shand. In another example, to help reduce or prevent interference, theantenna 180 may be a wireless antenna. Such a wireless antenna can bedisposed on the PCB 176 or may be positioned, at least in part, in or ona portion of the control device 120 that is separate and remote orspaced from the housing 160, as discussed further below.

The control device 120 also includes a controller 182, which in thisexample is also on the PCB 176. The controller 182 is operativelyconnected to the communication module 178 to perform electronicoperations such as generating the signals related to one or more ofshifting, pairing, derailleur trim operations, power management, and thelike. The controller 182 may be programmable and configurable togenerate signals to control the front and rear gear changers orderailleurs 74, 76, for example. In one example, the controller 182 maybe an Atmel ATmega324PA microcontroller with an internal EEPROM memory.The communication module 178 may also be programmable and configurableto likewise transmit and/or receive signals to control the front andrear gear changers 74, 76. In one example, the communication module 178may be an Atmel AT86RF231 2.4 GHz transceiver utilizing AES encryptionand DSS spread spectrum technology supporting 16 channels and the IEEE802.15.4 communication protocol. However, other suitablemicrocontrollers 182 and communication modules 178 may be utilized.Additionally, ancillary electrical and/or electronic devices andcomponents may be used, as is well known in the art, to further enhanceor enable the function and operation of the controller 182 and thecommunication module 178 and related components.

In one example, the control device 120 may include at least one lightemitting diode (LED) 184, which may also be positioned on the PCB 176.The LED 184 may convey status information to a user or a rider relatingto the electronic componentry and function of the actuator 136 orcontrol device 120. The LED 184 in this example may be visible through atransparent part (not shown) of the seal 174 and a transparent LEDwindow or cap 188 in or on the cover 170 of the cavity 168. In oneexample, the entire seal 174 may instead be transparent. Alternatively,only the part of the seal material that overlies the LED 184 may beconfigured to permit light through the seal 174.

Further, the electronic componentry may include one or more electricalswitches 190. The electrical switches 190, when actuated, may causeoperations to be carried out by the controller 182. Such operations mayrelate to signal transmission or reception, derailleur and controldevice 120 pairing, trim and/or shift operations, and the like. Theswitches 190 may generate signals to initiate or elicit an action and/orresponse from various mechanisms of the bicycle 50, such as the frontand rear electromechanical gear changers or derailleurs 74, 76.

In this example, the first electrical switch 190 may include a switch orbutton contact 194 on the PCB 176. The contact 194 can be positioned tounderlie a button 196, which can be positioned to cause the contact 194to engage or close. In this example, the first electrical switch 190 isactuated by depressing the button 196. The seal 174 may include amembrane or layer or a through hole at 198 (see below), which is alignedwith the switch contact 194 and the button 196. The cover 170 also hasat least a first switch hole 200 aligned with the membrane 198 in theseal 174 and via which the button 196 extends through the cover. Thebutton 196 can be spring or elastically biased outward through the hole200 in the cover 170 and can be depressed to actuate the switch 190 byengaging or closing the contact 194. In this example, the switch contact194 may thus be actuated through the seal 174 from outside the cavity168 and the cover 170. A user or rider operates the first electricalswitch 190 simply by depressing the button 196 toward the cover 170.

The button 196 may be integrally formed as a part of the seal 174, maybe attached to the seal material, or may be a separate switch part. Thebutton 196, if a separate part, may be attached to the PCB 176 (see FIG.7) or may be captured in part by the cover 170 against the outside ofthe seal 174. The button may pass through a hole at 198 in the seal 174if the button is connected directly to the PCB 176. Alternatively, thebutton 196 may operate through the membrane layer at 198 on the seal174, whereby the integrity of the seal for the cavity 168 is notcompromised. Other types of electrical switches may be used. The firstelectrical switch 190 may be an optional switch. The first electricalswitch 190 may be used for operations related to pairing the controldevice 120 with a specific bicycle component, such as the front or rearelectromechanical gear changers or derailleurs 74, 76, for trimming thederailleurs, or the like.

The electronic componentry on the PCB 176 and within the cavity 168 isretained and sealed in place in the cavity. The seal 174 overlies thePCB 176 and is sandwiched between the PCB and the cover 170 when thecover is fastened to the housing 160. Referring to FIGS. 6 and 7, theseal 174 may include a rib (not shown) around the perimeter of the sealmaterial. Likewise, the housing 160 may include a groove 202 around theopening into the cavity 168. The rib can seat in the groove 202 tocreate a tight environmental seal when the cover 170 is secured to thehousing 160. The material layer of the seal 174 may include raised orthickened regions, which may be positioned to coincide with electricalswitches, such as the switch 190, to encourage effective force transferfrom the switch actuators, such as the button 196, to the switchcontacts, such as the contact 194.

Referring to FIGS. 3, 4, and 8, the control device 120 also includes aset of cables, herein called a wiring harness 210. In this example, thewiring harness 210 may be a provided in a pre-assembled bundle. In thisexample, the wiring harness 210 includes a multiple pin connector 212that can be connected to the PCB 176 in a known manner. A power line 214extends from the connector 212 and has two wires 214 p, 214 n, which areconnected to positive and negative terminals, respectively, of the powersupply unit 164 of the control element 134, as discussed further below,to receive power to operate the electronic components. The wiringharness also has two auxiliary lines 216, 216A in this example. Eachauxiliary line 216, 216A extends from the connector 212 and terminatesat an auxiliary connector or jack 218, 218A, respectively. The housing160 includes routing grooves 220 adjacent and around at least part ofthe opening into the cavity 168. The power line 214 and auxiliary lines216, 216A are received in and guided by the routing grooves 220 to theirrespective destinations. The grooves 220 and lines 214, 216, 216A arecovered up by the cover 170 when the cover is installed on the housing160 over the cavity 168.

Referring to FIGS. 5A, 5B, and 6, the connection portion 166 of thecontrol element 134 in this example includes an accessory jack holder222 extending from the component portion 162. The holder 222 defines tworeceptacles 224 disposed side-by-side, each shaped to accepting andretain one of the jacks 218, 218A of the auxiliary lines 216, 216A. Thegroove 220 continues from the face of the housing 160 around the openingof the cavity 168 and splits into two separate slots 226. Each slot 226terminates adjacent a corresponding one of the receptacles 224 forguiding the respective auxiliary line 216 to the receptacle. Theaccessory jacks 218, 218A are thus connected to the PCB 176 and thus tothe power supply unit 164 via the auxiliary lines 216, 216A and theconnector 212 to receive power and to operate any components connectedto the jacks. Referring to FIGS. 5A and 6, a jack cover 225 can befastened to the holder 222 with fasteners 227 to capture the jacks 218,218A in the receptacles 224. The jack cover 225 can have shapedreceptacles (not shown) that also conform to the shape of the jacks 218,218A to aid in securely holding the jacks in place against the holder222.

In this example, the auxiliary jacks 218, 218A are carried on the endsof the auxiliary lines 216, 216A and are female connectors or jacks inthis example. Alternatively, each of the accessory jacks 218, 218A maybe formed integrally as a part of the holder 222 and the lines 216, 216Acould then be connected to the integral jacks. The control element 134can alternatively have no auxiliary jacks, one such jack, or more thantwo such jacks, if desired. A connector (not shown) for an optionalremote button, switch, or actuator 228 (see FIG. 2, for example, whichhas additional actuators 228 on the base bar or pursuit bar 94) may beconnected to the control device 120 through the accessory jack 218A ofthe connection portion 166 on the control element 134. The actuator 136in this example can be connected to the accessory jack 218 via a cableC, as shown in FIG. 3, utilizing one of the accessory jacks. In anotherexample, the actuator 136 could be hardwired to the control elementusing another cable connected to the wiring harness 210, leaving bothjacks 218, 218A accessible for connecting optional accessories or remoteactuators. In the disclosed example, the control element 134 providespower and electrical connection and operation between the actuator 136,the optional remote actuator 228, and the control element 134. Theaccessory jacks 218, 218A may be configured to accept connectors fromoptional additional and/or other remote electrical switches or otherdevices (not shown), as well as remote actuators 228, to connect them tothe control device 120. When no accessories or remote components areconnected to the control element 134, the accessory jacks 218, 218A maybe left open or may be sealed from moisture and contamination byinserting plugs (not shown) into the jacks.

In this example, the groove 220 and the slots 226 may be filled with anepoxy seal. Thus, when the cover 170 is installed, a watertight seal iscreated around the cover 170 as well as within the slots and grooves226, 220. The epoxy can secure the lines 214, 216, 216A in place and cancreate a seal that prevents water and other contaminants from reachingthe cavity 168. The epoxy seal material can also be used at theconnection between the jacks 218, 218A and the auxiliary lines 216,216A.

Still referring to FIGS. 5A, 5B, 6, and 7, in the disclosed example, thewires 214 p, 214 n of the power line 214 are connected to (+) and (−)terminals on the power supply unit 164 of the control element 134. Thepower supply unit 164 is configured to define a power supply, i.e., aself-contained battery unit as a part of the control element 134. Thus,the control element 134 in this example is a self-contained electricalassembly including a power supply, wireless communication electronics,and accessory connection capability.

The housing 160 at the power supply unit 164 is configured to create apower supply receptacle or case 232 and a battery cover 234. The powersupply case 232 is formed as a recess in the housing 160 and, in thisexample, is integrally formed as a part of the housing. In anotherexample, the power supply case may be a separate component that isfastened to the housing 160 via screws, snap features, adhesive, oranother suitable means. In this example, the power supply unit 164includes a conventional and replaceable coin cell type battery 236,which is received within a receptacle defined by the case 232 and opento the exterior of the housing 160. Alternatively, the power supply canbe a non-replaceable and/or rechargeable battery. The battery 236 may beconfigured to provide power to the PCB 176 for the antenna 180, thecontroller 182, and/or the LED 184, as well as to any remote switches oractuators 228 via the accessory jacks 218. The cover 234 is rotatable toinstall over the receptacle in the case 232 and can be reverse rotatedto be removed to access the battery 236. The cover 234 can include anelastomeric O-ring or gasket 238 around its periphery to create amoisture and contaminant proof seal against the case 232 on the housing160 when installed.

Referring to FIGS. 5A and 7, the power supply unit 164 includes thepositive and negative terminals or contacts on the back side of thepower supply case 232. These terminals can be connected to batterycontacts (not shown) within the receptacle of the case 232 to contactthe battery 236. The exposed contacts or terminals on the back side ofthe case 232 can be covered and encapsulated (and hidden as in FIG. 7)by an epoxy seal to secure the connections and to protect the contactsand the wires 214 p, 214 n from water, contaminants, and the elements.This epoxy seal could similarly be provided or replaced via a coverpiece that is attached to the back side of the case 232 via plasticwelding, fasteners, adhesive, or another suitable means.

The battery cover 234 may be secured via conventional mechanical threadsto the case 232. Instead, the cover 234 may be secured to the case 232via a set of tabs (not shown) or keys and slots or ways 240 that engageone another when the cover is twisted into place. In this example, theslots or ways 240 are on the cover and, thus, the corresponding tabs orkeys would be provided in the unseen receptacle in the case 232. Thereverse arrangement may also be used. The O-ring 238 is compressedbetween the cover 234 and the case 232 or a surface of the housing 160to provide a second seal for the power supply receptacle and battery 236against water and other contamination. The battery cover 234 and/or thecase 232 may also contain additional features among the cover 234 andcase 232 that, when engaged, inhibit unintentional movement of thebattery cover 234.

In one example of the present disclosure, a control device 120 ismountable to any portion of a handlebar arrangement or assembly, as longas the control element 134 is spaced from a gripping portion. In oneexample, the bicycle 50 may include a pair of the control devices 120,one on each of the left and right sides of the handlebar assembly 64. Asshown in FIG. 2, the handlebar assembly 64 includes the two barextensions 96, and each bar extension carries a control device 120,including an actuator 136. As shown in FIG. 3, the actuator cable Cextends along the interior of the bar extension 96 from the connectionportion 166 of the control element 134 and is connected to the actuator136. This arrangement can be provided within each of the left-hand andright-hand bar extensions 96L, 96R. Thus, the actuator 136 for each ofthe control devices 120 can be connected to a separate and distinctcontrol element 134.

One having ordinary skill in the art should understand that together thepair of control devices 120 may be configured to operate the respectivefront and rear electromechanical gear changers or derailleurs 74, 76.However, one should also understand that the control devices 120 may beutilized to operate other bicycle components as well. In one example,the pair of control devices 120 may be identical to one another or maybe different from one another, depending on the intended application foreach device. In another example, the two actuators 136 shown in FIG. 3could be connected to the same control element 120, one to each of thejacks 218 and 218A.

In the disclosed example, the configuration of the disclosed controldevice 120 may be varied and the configuration of the handlebar partinto which the control device is integrated may also be varied.Referring to FIGS. 9 and 10, an alternate example of a bar extension 250is illustrated. In the prior example, the bar extension 96 includes theopening 132 on a top side of the body 118 for access into thecompartment 133. In this example, the bar extension 250 includes anopening 252 on a side of a body 254 of the bar extension. Theconstruction of the control device 120 and the control element 134 inthis example is essentially the same as in the prior example. However,the control device 120 is installed into the body 254 of the barextension 250 from the side via the side opening 252. The body 254 inthis example again has a mounting portion 122 and a gripping portion 124that can be identical to the earlier described bar extension 96.However, the body 254 can have a modified transition portion 256 toaccommodate the side opening 252 and a different shaped compartment 258within the body to accommodate a different installation orientation forthe control element 134.

FIG. 11 shows an alternate example of a control device 260 installedwithin the bar extension 250 depicted in FIGS. 9 and 10. In thisexample, the control device 260 has a separate power supply unit 262,housing the power supply components, and a separate electrical unit 264housing the PCB, controller, LED, communication module, and the like. Inthis example, the actuator 136 is secured in the distal end D of thebody 254 of the bar extension 250 and is connected via a cable C to anauxiliary jack 266. In this example, the auxiliary jack 266 is loose andconnected to the power supply unit 262 and electrical unit 264 by a line268. Likewise, an auxiliary jack 270 is loose at the proximal end P ofthe body 254 on the bar extension 250 and is connect to the power supplyunit 262 and electrical unit 264 via a line 272. This exampleillustrates a different arrangement for an integrated bicycle controldevice provided as a part of a handlebar part for a bicycle.

FIG. 12 shows another example of a modified control device 280 that isintegrated into a bar extension 250 that is identical to that shown inFIGS. 9-11. In this example, most of the components of the controldevice 280 are similar to those of the control device of 260 of FIG. 11,including the power supply unit 262, electrical unit 264, cable C, jacks266, 270, and lines 268, 272. The only difference in this example isthat an actuator 282, which has a button 284, is secured to the distalend D of the body 254 by glue or an adhesive material instead of beingpress fit or friction fit. In this example, the actuator 282 does notinclude the press fit mechanism 156 of the prior examples.

FIG. 12 also generically illustrate a grip cover or handle cover 288,which can be received over the gripping portion 124 of the bar extension250. The grip cover 288 can be added to the exterior of the body 254over the gripping portion 124. The grip cover 288 can be shaped andsized to be comfortably grasped by a hand of a user or rider. As notedabove, the bar extension 250 can be formed of a carbon fiber material oranother suitable material of sufficient strength and rigidity, asdesired. The grip cover 288 can be formed of any suitable material, suchas natural and/or synthetic elastomeric materials and may be designed topresent a comfortable interface with the rider and to reduce thetendency to become detached or moved from its position on the exteriorof the gripping portion 124 of the bar extension 250. For example, thegrip cover 288 may be formed of a flexible thermoplastic elastomer (TPE)such as Santoprene™.

FIGS. 13-21 illustrate additional alternative examples of integratedbicycle control device arrangements. FIG. 13 shows two control devices290, one integrated into each of two handlebar parts, which may be timetrial bar extensions 292, of a bicycle. In this example, each controldevice 290 has a control element 294 with a power supply or battery 295,an actuator 136 at a distal end D of the bar extension 292, and anauxiliary jack 296 exposed at a proximal end P of the bar extension. Thecontrol element 294 is disposed at the transition portion of the barextension 292. In this example, a cable C for each actuator 136 ishardwired to the control element 294. Likewise, an auxiliary line 298 isconnected to the auxiliary jack 296 and is hardwired to the controlelement 294. An auxiliary cable R from a remote actuator (not shown,such as an actuator 228 on a base bar or pursuit bar) has a maleconnector 300 that can be inserted into the auxiliary jack 296. In thisexample, the auxiliary line 298 and jack 296 can be pushed into theproximal end P of the bar extension 292, which can then be cut to adesired length before being mounted, assembled, or installed on abicycle.

FIG. 14 shows two control devices 310, one integrated into each of twohandlebar parts, which again may be time trial bar extensions 312, of abicycle. In this example, each control device 310 has a control element314 with electronics only, an actuator 136 at a distal end D of the barextension 312, and an auxiliary port or jack (not shown) on the controlelement 314. The control element 314 is disposed at the transitionportion of the bar extension 312. In this example, a cable C for eachactuator 136 is hardwired to the control element 314. A power line 316is hardwired to the control element and extends through the proximal endP of the bar extension 312, terminating at a male connector 318. Aremote or external battery or power supply 320 is provide elsewhere on abicycle and has a port or jack (not shown) for the connector 318 toprovide power for the control device 310. An auxiliary cable R from aremote actuator (not shown, such as an actuator 228 on a base bar orpursuit bar) has a male connector 322 that can be inserted into theauxiliary port or jack on the control element 314. In this example, theauxiliary cable R and connector 322 can be disconnected from the controlelement 314 and withdrawn from the bar extension 312, which can then becut to a desired length before being mounted, assembled, or installed ona bicycle.

FIG. 15 shows two control devices 330, one integrated into each of twohandlebar parts, which may be time trial bar extensions 332, of abicycle. In this example, each control device 330 has a control element334 with electronics only, an actuator 336 at a distal end D of the barextension 332, and an auxiliary jack 338 exposed at a proximal end P ofthe bar extension. The control element 334 is disposed at the transitionportion of the bar extension 332. In this example, a cable C for eachactuator 336 is hardwired to the control element 334. Likewise, anauxiliary line 340 is connected to the auxiliary jack 338 and ishardwired to the control element 334. An auxiliary cable R from a remoteactuator (not shown, such as an actuator 228 on a base bar or pursuitbar) has a male connector 342 that can be inserted into the auxiliaryjack 338. The actuator 336 in this example carries a battery or powersupply 344 instead of the power source being part of the controlelement. Also, in this example, the auxiliary line 340 and jack 338 canbe pushed into the proximal end P of the bar extension 332, which canthen be cut to a desired length before being mounted, assembled, orinstalled on a bicycle.

In any of the foregoing examples, the antenna of the control device isprovided on the control element. In each example, the control elementcan be configured and oriented, when installed, to place the antenna ata furthest distance from the gripping part of the bar extension or otherhandlebar part. This can aid in minimizing any interference that mightbe caused by a rider's hand gripping the gripping part.

FIG. 16 shows two control devices 350, one integrated into each of twohandlebar parts, which may be time trial bar extensions 352, of abicycle. In this example, each control device 350 has a control element354, an actuator 356 integrated as a part of the control element anddisposed at a distal end D of the bar extension 352, and an auxiliaryjack 358 exposed at a proximal end P of the bar extension. In thisexample, the entire control element 354 and actuator 356 is fitted intothe distal end D of the bar extension 352. An auxiliary line 360 isconnected to the auxiliary jack 358 and is hardwired to the controlelement 354. An auxiliary cable R from a remote actuator (not shown,such as an actuator 228 on a base bar or pursuit bar) has a maleconnector 362 that can be inserted into the auxiliary jack 358. Thecontrol element 354 in this example carries a battery or power supply364 and the actuator 356. The antenna in this example, depicted by thesignal icon in this and other figures herein, can be positioned on thecontrol element 354 furthest from the distal end D to minimize anyinterference caused by a rider's hand gripping the gripping portion ofthe bar extension 352. In this example, the auxiliary line 360 and jack358 can be pushed into the proximal end P of the bar extension 352,which can then be cut to a desired length before being mounted,assembled, or installed on a bicycle.

FIG. 17 shows two control devices 370, one integrated into each of twohandlebar parts, which may be time trial bar extensions 372, of abicycle. In this example, each control device 370 has a control element374 with electronics only, an actuator 376 integrated as a part of thecontrol element and disposed at a distal end D of the bar extension 372,and an auxiliary jack 378 exposed at a proximal end P of the barextension. In this example, the control element 374 and actuator 376 isfitted into the distal end D of the bar extension 372. An auxiliary line380 is connected to the auxiliary jack 378 and is hardwired to thecontrol element 374. An auxiliary cable R from a remote actuator (notshown, such as an actuator 228 on a base bar or pursuit bar) has a maleconnector 382 that can be inserted into the auxiliary jack 378. Abattery or power supply 384 is separate from the control element 374 inthis example and is positioned in the transition portion of the barextension 372. The antenna in this example can again be positioned onthe control element 374 furthest from the distal end D to minimize anyinterference caused by a rider's hand gripping the gripping portion ofthe bar extension 372. In this example, the auxiliary line 380 and jack378 can be pushed into the proximal end P of the bar extension 372,which can then be cut to a desired length before being mounted,assembled, or installed on a bicycle.

FIG. 18 shows two control devices 390A, 390B, one integrated into eachof two handlebar parts, which may be time trial bar extensions 392, of abicycle. As noted above and as illustrated by this example, one bicyclemay have two integrated bicycle control devices that are not identicalto one another. In this example, each control device 390A, 390B has acontrol element 394 with electronics only, an actuator 396 integrated asa part of the control element and disposed at a distal end D of the barextension 392, and an auxiliary jack 398 exposed at a proximal end P ofthe bar extension. In this example, the control element 394 and actuator396 is fitted into the distal end D of the bar extension 392. Anauxiliary line 400 is connected to the auxiliary jack 398 and ishardwired to the control element 394. An auxiliary cable R from a remoteactuator (not shown, such as an actuator 228 on a base bar or pursuitbar) has a male connector 402 that can be inserted into the auxiliaryjack 398.

Each of the control devices 390A, 390B has a remote or external powersource 404 that is positioned elsewhere on the bicycle. The antenna inthis example can again be positioned on the control element 394 furthestfrom the distal end D to minimize any interference caused by a rider'shand gripping the gripping portion of the bar extension 372. In thisexample, the auxiliary line 400 and jack 398 can be pushed into theproximal end P of the bar extension 392, which can then be cut to adesired length before being mounted, assembled, or installed on abicycle.

For the control device 390A, the external power source 404 is connectedat a T junction to the auxiliary cable R. Thus, the auxiliary cable Rwill be connected to the auxiliary jack 398 to provide power for thecontrol device 390A, regardless as to whether a remote actuator or othercomponent is connected to the cable R. For the control device 390B, theexternal power source is connected to a separate jack 406, which ishardwired by an auxiliary line 408 to the control element.

FIG. 19 shows two control devices 410, one integrated into each of twohandlebar parts, which may be time trial bar extensions 412, of abicycle. In this example, each control device 410 has a control element414 with a power source 415, an actuator 136 at a distal end D of thebar extension 412, a first port or jack (not shown) on the controlelement for connecting the actuator, and an auxiliary port or jack (notshown) on the control element. In this example, the control element 414is disposed at the proximal end P of the bar extension 412. In thisexample, a cable C for each actuator 136 has a male connector 416 forconnecting the cable and actuator 136 to the first port or jack on thecontrol element 414. Likewise, an auxiliary an auxiliary cable R from aremote actuator (not shown, such as an actuator 228 on a base bar orpursuit bar) has a male connector 418 that can be inserted into theauxiliary port or jack on the control element 414. In this example, thecontrol element 414 should be removable from the proximal end P of thebar extension 412 in order to then cut the bar extension to a desiredlength before being mounted, assembled, or installed on a bicycle.

FIG. 20 shows two control devices 420, one integrated into each of twohandlebar parts, which may be time trial bar extensions 422, of abicycle. In this example, each control device 420 has a control element424 with electronics only, an actuator 426 at a distal end D of the barextension 422, a first port or jack (not shown) on the control elementfor connecting the actuator, and an auxiliary port or jack (not shown)on the control element. In this example, the control element 424 isdisposed at the proximal end P of the bar extension 422. In thisexample, a cable C for each actuator 426 has a male connector 428 forconnecting the cable and actuator 426 to the first port or jack on thecontrol element 424. Likewise, an auxiliary an auxiliary cable R from aremote actuator (not shown, such as an actuator 228 on a base bar orpursuit bar) has a male connector 430 that can be inserted into theauxiliary port or jack on the control element 424. The actuator 426 inthis example carries a battery or power supply 432 instead of the powersource being part of the control element. In this example, the controlelement 424 should be removable from the proximal end P of the barextension 422 in order to then cut the bar extension to a desired lengthbefore being mounted, assembled, or installed on a bicycle.

FIG. 21 shows two control devices 440, one integrated into each of twohandlebar parts, which may be time trial bar extensions 442, of abicycle. In this example, each control device 440 has a control element444 with electronics only, an actuator 136 at a distal end D of the barextension 442, a first port or jack (not shown) on the control elementfor connecting the actuator, and an auxiliary port or jack (not shown)on the control element. In this example, the control element 444 isdisposed at the proximal end P of the bar extension 442. In thisexample, a cable C for each actuator 136 has a male connector 446 forconnecting the cable and actuator 136 to the first port or jack on thecontrol element 444. Likewise, an auxiliary an auxiliary cable R from aremote actuator (not shown, such as an actuator 228 on a base bar orpursuit bar) has a male connector 448 that can be inserted into theauxiliary port or jack on the control element 444. A remote or externalbattery or power supply 450 is hardwired via a power line 452 to thecontrol element 444 instead of the power source being part of thecontrol element. In this example, the control element 444 should beremovable from the proximal end P of the bar extension 442 in order tothen cut the bar extension to a desired length before being mounted,assembled, or installed on a bicycle.

Numerous examples of integrated bicycle control devices are disclosedand described herein. In each example, the control element or othercontrol device components can be secured or otherwise fastened directlyin the corresponding compartment within the handlebar part, i.e., theprimary mounting structure. Alternatively, the compartment can be shapedto closely follow the shape of the control element or other controldevice component so that the component can be generally held in placewithin the compartment. In another example, the control element or othercomponents, including such components having no separate distincthousing or case, may be loosely held in the corresponding compartmentwithin the handlebar part. In another alternative, one or more secondarymounting structures may be utilized within the handlebar part or primarymounting structure to secure the control element or other control devicecomponents in place.

The structure and function of the handlebar part can vary from thedisclosed time trial type bar extensions. The material from which suchhandlebar parts are fabricated can also vary. The parts can be made fromcarbon fiber material, aluminum, or the like. The primary mountingstructure of the disclosed control devices may extend into the mountingportion of the handlebar part. The secondary mounting structures of thedisclosed control devices may have a mating surface formed of the samematerial as primary mounting structure and/or may be designed to matewith the primary mounting structure, the housing or case of the controlelement, the housing of other components, and/or one or more of thecomponents of the control device.

The secondary mounting structures may be disposed within the primarymounting structure at or adjacent to the gripping portion. In oneexample, the secondary mounting structure may include a lugged aluminummounting structure. The secondary mounting structure may be co-formedwithin the primary mounting structure and may extend axially fromgripping portion. The secondary mounting material structure may bedisposed within the primary mounting structure near the transitionportion.

The power supply, i.e., the power supply or battery, may be disposed inthe gripping portion, may be contained within a housing, and/or may bemounted to or with at least one mounting structure. The power supply maybe included in the same housing as the wireless communication module ormay be disposed in a separate housing from the wireless communicationmodule. The power supply may be disposed in the transition portion ofthe handlebar part, contained within a housing, and mounted to at leastone of the mounting structures. The power supply can instead be disposedin the mounting portion and be mounted to a mounting structure withinthe handlebar part. The power supply may be an external power supply,positioned remote from the handlebar part and control deviceelectronics.

The wireless communication module may be disposed in the grippingportion, contained within a housing, and mounted to or with at least oneof the aforementioned mounting structures. The wireless communicationmodule may be in the same housing as the power supply or may be disposedin a housing separate from the power supply. The wireless communicationmodule may be disposed in the transition portion, contained within ahousing, and mounted to or with at least one of the aforementionedmounting structures. The wireless communication module may be disposedin the mounting portion and mounted using the primary mountingstructure.

The switch or switches may be disposed in the gripping portion andmounted to or with at least one of the aforementioned mountingstructures. The switch or switches may be disposed in the same housingas the wireless communication module, the same housing as the powersupply, or both. The switch may be mounted in the gripping portion ofthe primary mounting structure in electric communication with thewireless communication module and/or power supply.

The auxiliary port or jack connection may be or include an electricalinput that is flexible and extends through the bicycle control device.The auxiliary port or jack may extend at least partially beyond the endof the mounting portion and may provide electrical input to the wirelesscommunication module located in either the transition portion or thegripping portion.

The LED can be arranged within or on the bicycle control device toprovide visible or visual input to the bicycle rider. The LED can bedisposed or arranged in the gripping portion or the transition portion.The LED may be disposed in the gripping portion above a center axis ofthe gripping portion and within the housing of the wirelesscommunication module.

The grip cover covers the gripping portion and may extend onto thetransition portion. In one example, the grip cover may be about 100 to150 mm in length. The grip cover can be made from a flexible materialand shaped for ergonomic gripping by a rider. The grip cover may haveinterlocking features with either or both of the primary or secondarymounting structures to aid in retaining the grip cover in position onthe handlebar part. The grip cover may contain cutouts or designfeatures, such as shapes, textures, colors, and/or the like to allow foraccess to or indication of where a switch is located on the bicycle.

In an embodiment, a handlebar part of a bicycle handlebar assembly isprovided. The handlebar part may include a body having a grippingportion and a transition portion spaced from the gripping portion, acompartment formed in the transition portion, and/or a control deviceintegrated into the body. The control device may include an actuatorcoupled to the handlebar part adjacent the gripping portion and acontrol element received within the compartment. The control element mayinclude a controller configured to generate a signal in response toactuation of the actuator, and a communication module configured totransmit the signal.

The handlebar part of the embodiment may also include an LED in thecontrol element. The LED may be visible from outside the handlebar part.The handlebar part may be formed as a bar extension configured to beconnected to a handlebar assembly. In an example, the body has amounting portion adjacent a proximal end of the body and the transitionportion disposed between the mounting portion and the gripping portion.

In an example, the handlebar part may also include an opening to thecompartment on a top and/or a side of the body.

In another example, the gripping portion is adjacent a distal end of thebody.

In an embodiment, the handlebar part also includes an antenna incommunication with the controller, and/or a power supply for providingpower to the controller and the communication module. In an example, theantenna and/or the power supply is provided as a part of the controlelement.

In this, or another embodiment, the control device also includes anopening in the body to permit access to the compartment, and a removablecover attachable to the body to cover the opening and close thecompartment.

In an embodiment, an integrated bicycle control device is provided. Thecontrol device may include a handlebar part of a bicycle handlebarassembly. The handlebar part may have a body with a gripping portionadjacent a distal end of the body, a mounting portion adjacent aproximal end of the body, and a transition portion spaced from anddisposed between the gripping portion and the mounting portion. Thehandlebar part may also include a compartment formed in the body and anopening in the body to permit access to the compartment. An actuator maybe disposed at or near the distal end of the body. A control element maybe received in the compartment. The control element may include ahousing and a controller in the housing configured to generate a signalin response to actuation of the actuator. The bicycle control may alsoinclude an antenna in communication with the controller, wherein theantenna is positioned along the body spaced from the distal end and thegripping portion. The actuator may be connected to the control element.

In an embodiment, the antenna is disposed along the transition portionof the body.

In an embodiment, the compartment is in the transition portion.

In an embodiment the antenna is in the housing of the control element.

Although certain integrated bicycle control devices, features, aspects,parts, components, and characteristics have been described herein inaccordance with the teachings of the present disclosure, the scope ofcoverage of this patent is not limited thereto. On the contrary, thispatent covers all embodiments of the teachings of the disclosure thatfairly fall within the scope of permissible equivalents.

The illustrations of the embodiments described herein are intended toprovide a general understanding of the structure of the variousembodiments. The illustrations are not intended to serve as a completedescription of all of the elements and features of apparatus and systemsthat utilize the structures or methods described herein. Many otherembodiments may be apparent to those of skill in the art upon reviewingthe disclosure. Other embodiments may be utilized and derived from thedisclosure, such that structural and logical substitutions and changesmay be made without departing from the scope of the disclosure.Additionally, the illustrations are merely representational and may notbe drawn to scale. Certain proportions within the illustrations may beexaggerated, while other proportions may be minimized. Accordingly, thedisclosure and the figures are to be regarded as illustrative ratherthan restrictive.

While this specification contains many specifics, these should not beconstrued as limitations on the scope of the invention or of what may beclaimed, but rather as descriptions of features specific to particularembodiments of the invention. Certain features that are described inthis specification in the context of separate embodiments can also beimplemented in combination in a single embodiment. Conversely, variousfeatures that are described in the context of a single embodiment canalso be implemented in multiple embodiments separately or in anysuitable sub-combination. Moreover, although features may be describedabove as acting in certain combinations and even initially claimed assuch, one or more features from a claimed combination can in some casesbe excised from the combination, and the claimed combination may bedirected to a sub-combination or variation of a sub-combination.

Similarly, while operations and/or acts are depicted in the drawings anddescribed herein in a particular order, this should not be understood asrequiring that such operations be performed in the particular ordershown or in sequential order, or that all illustrated operations beperformed, to achieve desirable results. In certain circumstances,multitasking and parallel processing may be advantageous. Moreover, theseparation of various system components in the embodiments describedabove should not be understood as requiring such separation in allembodiments, and it should be understood that any described programcomponents and systems can generally be integrated together in a singlesoftware product or packaged into multiple software products.

One or more embodiments of the disclosure may be referred to herein,individually and/or collectively, by the term “invention” merely forconvenience and without intending to voluntarily limit the scope of thisapplication to any particular invention or inventive concept. Moreover,although specific embodiments have been illustrated and describedherein, it should be appreciated that any subsequent arrangementdesigned to achieve the same or similar purpose may be substituted forthe specific embodiments shown. This disclosure is intended to cover anyand all subsequent adaptations or variations of various embodiments.Combinations of the above embodiments, and other embodiments notspecifically described herein, are apparent to those of skill in the artupon reviewing the description.

The Abstract of the Disclosure is provided to comply with 37 C.F.R. §1.72(b) and is submitted with the understanding that it will not be usedto interpret or limit the scope or meaning of the claims. In addition,in the foregoing Detailed Description, various features may be groupedtogether or described in a single embodiment for the purpose ofstreamlining the disclosure. This disclosure is not to be interpreted asreflecting an intention that the claimed embodiments require morefeatures than are expressly recited in each claim. Rather, as thefollowing claims reflect, inventive subject matter may be directed toless than all of the features of any of the disclosed embodiments. Thus,the following claims are incorporated into the Detailed Description,with each claim standing on its own as defining separately claimedsubject matter.

It is intended that the foregoing detailed description be regarded asillustrative rather than limiting and that it is understood that thefollowing claims including all equivalents are intended to define thescope of the invention. The claims should not be read as limited to thedescribed order or elements unless stated to that effect. Therefore, allembodiments that come within the scope and spirit of the followingclaims and equivalents thereto are claimed as the invention.

1. An integrated bicycle control device comprising: a handlebar part ofa bicycle handlebar assembly for a bicycle, the handlebar part having abody with a gripping portion adjacent a distal end of the body andhaving a transition portion spaced from the gripping portion; acompartment formed in the transition portion; an actuator disposed at ornear the distal end of the body; and a control element disposed withinthe compartment, the control element including a controller configuredto generate a signal configured to control a component of the bicycle inresponse to actuation of the actuator.
 2. The integrated bicycle controldevice of claim 1, wherein the handlebar part includes a mountingportion adjacent a proximal end of the body, and wherein the transitionportion is disposed between the mounting portion and the grippingportion.
 3. The integrated bicycle control device of claim 2, whereinthe handlebar part is bent between mounting portion and the grippingportion.
 4. The integrated bicycle control device of claim 2, whereinthe transition portion has a cross section shape that is different froma cross section shape of the gripping portion, the mounting portion, orboth.
 5. The integrated bicycle control device of claim 4, wherein thegripping portion has an interior with a maximum width or diameter thatis smaller than a maximum width or diameter of the compartment withinthe transition portion.
 6. The integrated bicycle control device ofclaim 5, wherein the control element has a size that is too large to fitwithin the interior of the gripping portion but not too large to fitwithin the compartment.
 7. The integrated bicycle control device ofclaim 1, wherein the gripping portion has an interior with a maximumwidth or diameter that is smaller than a maximum width or diameter ofthe compartment within the transition portion.
 8. The integrated bicyclecontrol device of claim 7, wherein the control element has a size thatis too large to fit within the interior of the gripping portion but nottoo large to fit within the compartment.
 9. The integrated bicyclecontrol device of claim 1, wherein an opening into the body is disposedon a top of the body.
 10. The integrated bicycle control device of claim1, wherein an opening into the body is disposed on a side of the body.11. The integrated bicycle control device of claim 1, wherein thehandlebar part is a bar extension having a mounting portion adjacent aproximal end of the body, and wherein the bar extension is configured toextend forward on a bicycle when the mounting portion is connected tothe bicycle.
 12. The integrated bicycle control device of claim 1,further comprising: an opening in the body to permit access to thecompartment.
 13. The integrated bicycle control device of claim 12,further comprising: a removable cover attachable to the body to coverthe opening and close the compartment.
 14. The integrated bicyclecontrol device of claim 13, wherein the removable cover and the openinginto the body are disposed on a side of the body.
 15. The integratedbicycle control device of claim 1, wherein a portion of the transitionportion is transparent to radio frequency transmission signals.
 16. Theintegrated bicycle control device of claim 15, wherein the radiofrequency transparent portion is a removable cover attachable to thebody to cover an opening and close the compartment.
 17. The integratedbicycle control device of claim 16, wherein the body is made from acarbon fiber material and the cover is not made from a carbon fibermaterial.
 18. The integrated bicycle control device of claim 1, furthercomprising: a power supply case coupled to the body, the power supplycase configured to contain a power supply for providing power to thecontroller; and a removable cover closing off the power supply case. 19.The integrated bicycle control device of claim 1, further comprising: abattery providing power to the control element and positioned remotefrom the control element.
 20. The integrated bicycle control device ofclaim 1, further comprising: an antenna in communication with thecontroller, wherein the antenna is positioned along the transitionportion of the handlebar part.
 21. The integrated bicycle control deviceof claim 1, wherein the actuator is connected by a cable to the controlelement.